Baxi Barcelona Installation And Servicing Instructions

Baxi Barcelona

Wall Mounted Powered Flue Condensing Boiler
Gas Fired Central Heating Unit

Installation and
Servicing Instructions

BAXI

Page 2

Natural Gas

Baxi Barcelona

G.C.Nº 41 075 02
Baxi Limited is one of the leading manufacturers of domestic

heating products in the UK.
Our first priority is to give a high quality service to our

customers. Quality is designed into every Baxi product ­products which fulfil the demands and needs of customers,
offering choice, efficiency and reliability.

To keep ahead of changing trends, we have made a
commitment to develop new ideas using the latest
technology - with the aim of continuing to make the products
that customers want to buy.

The boiler meets the requirements of Statutory Instrument
“The Boiler (Efficiency) Regulations 1993 Nº 3083” and is
deemed to meet the requirements of Directive 92/42/EEC on
the energy efficiency requirements for new hot water boilers
fired with liquid or gaseous fuels:-

Baxi is also the largest manufacturing partnership in the
country. Everyone who works at the company has a
commitment to quality because, as shareholders, we know
that satisfied customers mean continued success.

We hope you get a satisfactory service from Baxi. If not,
please let us know.

Baxi is a BS-EN ISO 9001
Accredited Company

Type test for purpose of Regulation 5 certified by:
Notified Body 0086.

Product/Production certified by:
Notified Body 0086.

For GB/IE only.

Contents – page 3

Section

Page

1.0

2.0

3.0

4.0

5.0

6.0

7.0

8.0

9.0

10.0

11.0

Introduction

General Layout

Appliance Operation

Technical Data

Dimensions and Fixings

System Details

Site Requirements

Installation

Electrical

Commissioning the Boiler

Fitting the Outer Case

4

5

6

7

8

9

12

16

22

24

25

12.0

13.0

14.0

15.0

Servicing the Boiler

Changing Components

Short Parts List

Fault Finding

26

28

35

36

1.0 Introduction – page 4

Fig.1

Fig. 2

Baxi Limited declare that no substances harmful to health
are contained in the appliance or used during appliance
manufacture.

NOTE: This appliance must be installed in accordance with
the manufacturer’s instructions and the regulations in force,
and only used in a suitably ventilated location.

All systems must be thoroughly flushed and treated
with inhibitor (see Section 6.2).

Read the instructions fully before installing or using the
appliance

1.1 Description

1. The Baxi Barcelona is a gas fired room sealed fan
assisted condensing central heating boiler.

2. The maximum output of the boiler is preset at 80,000
Btu/hr. The boiler will automatically adjust down to
30,000 Btu/hr according to the system load. If required,
the output can be set to 100,000 Btu/hr. Please refer to
section 8.8.

3. It is designed for use on Natural Gas (G20).

4. The boiler is suitable for fully pumped open vented
central heating and domestic hot water systems and
sealed systems.

5. A label giving details of the model, serial number and
Gas Council number is situated on the rear of the lower
door panel (Fig. 1).

6. The boiler data badge is positioned on the air box door
(Fig. 2).

7. The boiler is intended to be installed in residential /
commercial / light industrial E.M.C. environments on a
governed meter supply only.

8. The boiler must be installed with one of the purpose
designed flues such as the standard horizontal flue kit,
part nº 236921.

“Benchmark” Log Book

As part of the industry-wide “Benchmark” initiative all Baxi
boilers now include an Installation, Commissioning and
Service Record Log Book. Please read the Log Book
carefully and complete all sections relevant to the
appliance and installation. These include sections on the
type of controls employed, flushing the system, burner
operating pressure etc. The details of the Log Book will be
required in the event of any warranty work. Also, there is a
section to be completed at each subsequent regular
service visit.

1.2 Important Information

This product contains Refractory Ceramic Fibres (R.C.F.)
which are man-made vitreous silicate fibres. Excessive
exposure to these materials may cause temporary irritation
to eyes, skin and respiratory tract. Care must be taken when
handling these articles to ensure the release of dust or fibres
is kept to a minimum.

To ensure that the release of fibres from these articles is
kept to a minimum, during installation and servicing it is
recommended that a HEPA. filtered vacuum is used to
remove any dust, soot or other debris accumulated in and
around the appliance. This should be performed before and
after working on the installation.

It is recommended that any replaced item(s) are not broken
up but sealed within heavy duty polythene bags and clearly
labelled “R.C.F. waste”. This is not classified as “hazardous
waste” and may be disposed of at a tipping site licensed for
the disposal of industrial waste.

Protective clothing is not required when handling these
articles but it is recommended that gloves are worn and the
normal hygiene rules of not smoking, eating or drinking in
the work area are followed and always wash hands before
eating or drinking.

2.0 General Layout – page 5

2.1 Layout (Figs. 3,4 & 5)

1. Wall Plate

2. Flue Elbow

3. Heat Exchanger

4. Burner

5. Air Box

6. Fan Protection Thermostat

7. Fan Assembly

8. Condensate Trap

9. User Interface (optional timer available)

10. Gas Tap

11. Gas / Air Ratio Valve

12. Electronics Housing

13. Transformer

14. Flow Pipe Connection

15. Return Pipe Connection

16. Flow Temperature Safety Thermostat - Black

17. Flow Temperature Thermistor - Red

18. Flow Switch (dry fire protection)

2.2 Optional Extras

KIT PART Nº
FLUE EXTENSION KITS (110/70)
Flue Extension 0.25M 241692
Flue Extension 0.5M 241694
Flue Extension 1 M (Use two kits for 2M etc.) 241695
Flue Bend x 2 – 45º (Reduce overall length

of flue by 0.5m when fitting this bend) 241689
Flue Bend – 90º (Reduce Overall length of

flue by 1m when fitting each bend) 241687
VERTICAL FLUE (110/70)

Vertical Flue Terminal 242802
Vertical Boiler Connection 242886
CONTROL ACCESSORIES

Integral Electronic Twin Channel Timer Kit 242834

3.0 Appliance Operation – page 6

3.1

1. Pump Overrun: When the switched live to the boiler
switches on or the flow temperature is greater than the
set point or anti-cycle finishes then Pump Overrun
occurs for 10 seconds (cold) or 60 seconds (hot). The
pump is on while the fan, spark generator and gas
valve are off.

2. Fan Purge: When pump overrun has finished if the flow
temperature is less than that set on the thermostat
knob then Fan Purge occurs. The pump and fan are on
while the spark generator and gas valve are off.

3. Ignition: When fan purge has finished Ignition occurs.
The pump, fan, spark generator and gas valve are on.
The burner ignites at mid rate.

4. Burner On: When a flame is detected during the
ignition period then Burner On occurs. The pump, fan
and gas valve are on while the spark generator is off.
Flow temperature is controlled by varying the fan speed
(and thereby the gas rate) to achieve optimum
operation.

5. Anti-cycle: When all the TRVs shut down during
Burner On or Pump Overrun finishes and flow
temperature is greater than set point then Anti-cycle
occurs. The pump, fan, spark generator and gas valve
are switched off.

6. Ignition Lockout: When 5 ignition attempts have been
made without a flame being detected then Ignition
Lockout occurs. The pump, fan, spark generator and
gas valve are switched off. The lockout light flashes
once a second. The boiler can only be reset manually
using the thermostat knob.

7. No Water Flow: When there is No Water Flow through
the boiler (indicated by the flow switch) then a
continuous cycle of Pump Overrun and Anti-cycle
occurs.

4.0 Technical Data – page 7

5.0 Dimensions and Fixings – page 8

Fig. 6

DIMENSIONS
A 600mm
B 320mm
C 390mm
D l25mm Ø Min.
E 150mm
F 125mm

The 3º (1 in 20) fall provided by the elbow is
to allow condensate to run back to the boiler,
for disposal through the condensate
discharge pipe.

Fig 7

SIDE FLUE (left and right)

For every 1 m of horizontal flue length,
the clearance above the top of the flue
elbow should be 55mm to incorporate
the 3º (1 in 20) fall in the flue from the
terminal to the elbow.

Flue length (Y) Clearance (X)

Up to1m 55mm
1m-2m 110mm
2m-3m 165mm

6.0 System Details – page 9

Fig. A Wiring to the pump feed connection of boiler

6.1 Water Circulating Systems

1. The appliance is suitable for use with open vent fully
pumped systems and sealed systems.

The following conditions should be observed on all
systems:

• The static head must not exceed 30m (100ft) of water.

• The boiler must not be used with a direct cylinder.

• Drain cocks should be fitted to all system low points.

• All gas and water pipes and electrical wiring must be

installed in a way which would not restrict the servicing
of the boiler.

• Position isolating valves as close to circulating pump as
possible.

• It is recommended that the return pipe is fitted with an
automatic air vent as close to the boiler as is practical.

NOTE: Full TRV Systems (refer to section 6.4) Where all
the radiators are controlled by TRV’s then pump protection
will be required. This can be done by either of the options
opposite (see Fig A & B). The option shown in Fig. A

should only be used on a full TRV system without a
bypass. Fig. B shows a system with a bypass that must
be capable of allowing a flow of at least 3 l/mm.

Fig. B Providing a 3 l/mm bypass

6.2 Treatment of Water Circulating Systems

• All recirculatory water systems will be subject to
corrosion unless an appropriate water treatment is
applied. This means that the efficiency of the system
will deteriorate as corrosion sludge accumulates within
the system, risking damage to pump and valves, boiler
noise and circulation problems.

• When upgrading existing systems that exhibit evidence
of sludging, it is advisable to clean the system prior to
treatment in order to remove any sludge and reduce the
likelihood of these deposits damaging new
components.

• When fitting new systems flux will be evident within the
system, which can lead to damage of system
components.

• All systems must be thoroughly drained and flushed
out. The recommended flushing and cleansing agents
are Betz-Dearborn Sentinel X300 or X400 and Fernox
Superfloc Universal Cleanser which should be used
following the flushing agent manufacturer’s instructions.

• System additives - corrosion inhibitors and flushing
agents/descalers should be suitable for aluminium and
comply to BS7593 requirements. The only system
additives recommended are Betz-Dearborn Sentinel
X100 and Fernox-Copal which should be used following
the inhibitor manufacturer’s instructions.

Failure to flush and add inhibitor to the system will
invalidate the appliance warranty.

• It is important to check the inhibitor concentration after
installation, system modification and at every service in
accordance with the manufacturer’s instructions. (Test
kits are available from inhibitor stockists.)

• For information or advice regarding any of the above
contact the Baxi Helpline.

6.0 System Details – page 10

Fig. 7a

Fig. 8 Typical Low Head Installation

Fig. 9 If Conditions Require,

This System Possible

6.3 Pipework

1. The sizes of flow and return pipes from the boiler
should be determined by normal methods, according to
the requirements of the system. The connection to the
boiler is 28mm (compression).

2. Due to space requirements within the boiler outercase,
pipework should comprise of solder fittings.

3. A 20ºC (36ºF) drop in temperature across the system is
recommended for condensing boilers. Existing radiators
may be oversized and so allow this, but where radiator
sizing is marginal it may be advisable to retain a system
temperature drop of 11ºC (20ºF).

4. In systems using non-metallic pipework it is necessary
to use copper pipe for the boiler Flow and Return. The
copper must extend at least 1 metre from the boiler and
include any branches (Fig. 7a).

6.4 System Controls

1. For optimum operating conditions, the heating system
into which the boiler is installed should include a control
system.

2. Such a system will comprise of a timer control and
separate room or cylinder thermostats as appropriate.
(An integral twin channel programmer is available as an
optional extra).

3. The boiler should be controlled so that it operates on
demand only.

4. Operation of the system under control of the boiler
thermostat & TRV’s only does not produce the best
results.

Fig. 10 Alternative Low Head Installation

6.5 Low Head Installation

1. Using a close couple arrangement the minimum head is
as shown in the diagrams (Figs. 8 & 9) subject to the
following conditions:

a) The pump being adjusted to give an 20ºC drop across

the boiler.

b) The pump must be fitted on the flow.
c) The pump must be fitted in accordance with the pump

manufacturers instructions.

d) The open vent pipe must be taken up from a tee in a

horizontal section of the flow pipe.
An alternative Low Head Installation (Fig. 10)

2. For heads below 400mm then a combined vent and
feed pipe may be connected. This must be a minimum
of 22mm diameter. It is recommended that an air
separator is fitted when using a combined feed and
vent pipe.

6.6 Thermal Stores

1. The Barcelona must not be fitted to thermal stores
which override the boiler control system.

6.0 System Details – page 11

Fig 11

6.7 Sealed Systems (Fig. 11)

1. SAFETY VALVE - A safety valve complying with the
requirements of BS 6750 Part 1 must be fitted close to
the boiler on the flow pipe by means of a horizontal or
vertically upward connection with no intervening valve
or restrictions and should be positioned to facilitate
testing. The valve should be pre-set and non-adjustable
to operate at a pressure of 3 bar (45 lbf/in²). It must be
arranged to discharge any water or steam through a
pipe to a safe outlet position.

2. PRESSURE GAUGE - A pressure gauge of minimum
range 0-4 bar (0-60 lbf/in²) with a fill pressure indicator
must be fitted to the system, preferably at the same
point as the expansion vessel in an easily visible
position.

3. EXPANSION VESSEL - An expansion vessel
complying with the requirements of BS 4814 must be
fitted to the system by means of a connection close to
the inlet side of the circulating pump in accordance with
the manufacturers instructions, the connecting pipe
being unrestricted and not less than 15mm (½ in)
nominal size. The volume of the vessel should be
suitable for the system water content and the nitrogen
or air charge pressure should not be less than the
system static head (See Table. 1).

Table 1

NOTE

Where a vessel of the calculated size is not obtainable

then the next available larger size should be used.

Further details of sealed system design can be
obtained from BS 5449 and the British Gas publication
entitled Specifications for Domestic Wet Central
Heating Systems’.

4. FILLING POINT - A filling point and an approved stop
valve to BS 1010 must be fitted at low level and the
method used for filling the system should be approved
by the local water undertaking. For further details see
BS 6798.

5. MAKE UP SYSTEM - A method of replacing water lost
from the system should be provided either by means of
a make up vessel of not more than 3 litres (5 pints)
capacity, mounted above the highest point of the
system, or by re-pressurisation of the system.

6. VENTING - A method of venting the system during
filling and commissioning must be provided by fining
automatic air vents or by venting manually.

7. HOT WATER STORAGE - The hot water storage
vessel must be of the indirect coil type. All components
used in the system must be suitable for operation at
110ºC (230ºF) and at the pressure allowed by the
safety valve.

7.0 Site Requirements – page 12

Fig. 12

7.1 Information

WARNING - Check the information on the data plate is compatible

with local supply conditions

1. The installation must be carried out by a CORGI Registered
Installer or other registered competent person and be in
accordance with the relevant requirements of the current GAS

SAFETY (Installation and Use) REGULATIONS, the
BUILDING REGULATIONS (Scotland)(Consolidation), the
LOCAL BUILDING REGULATIONS, the current I.E.E.
WIRING REGULATIONS and the bye laws of the LOCAL
WATER UNDERTAKING. Where no specific instruction is
given reference should be made to the relevant BRITISH
STANDARD CODES OF PRACTICE. For Ireland install in
accordance with IS 813 “INSTALLATION OF GAS
APPLIANCES”. Reference should also be made to BRITISH
GAS GUIDANCE NOTES FOR THE INSTALLATION OF
DOMESTIC GAS CONDENSING BOILERS.

7.2 B.S. Codes of Practice

Standard Scope

BS 6891 Gas Installation
BS 5546 Installation of hot water supplies for domestic

purposes.
BS 5449 Part 1 Forced circulation hot water systems
BS 6798 Installation of gas fired hot water boilers.
BS 5440 Part 1 Flues
BS 5440 Part 2 Ventilation
BS 7074 Expansion vessels and ancillary equipment for

sealed water systems.
BS 7593 Treatment of water in domestic hot water

central heating systems

Fig. 13

WARNING - The addition of anything that may interfere with the

normal operation of the appliance without the express written
permission of Baxi Limited could invalidate the appliance warranty
and infringe the GAS SAFETY (Installation and Use)

REGULATIONS.

7.3 Clearances (Figs. 12 &13)

1. A flat vertical area is required for the installation of the boiler.

2. These dimensions include the necessary clearances around

the boiler for case removal, spanner access and air movement.
Additional clearances may be required for the passage of pipes
around local obstructions such as joists running parallel to the
front face of the boiler.

7.4 Location

1. The boiler may be fitted to any suitable wall with the flue

passing through an outside wall or roof and discharging to
atmosphere in a position permitting satisfactory removal of
combustion products and providing an adequate air supply.
The boiler should be fitted within the building unless otherwise
protected by a suitable enclosure i.e. garage or outhouse. (The
boiler may be fitted inside a cupboard - see Section 7.5).

2. If the boiler is sited in an unheated enclosure then it is

recommended to incorporate an appropriate device for frost
protection in the system controls.

3. If the boiler is fitted in a room containing a bath or shower

reference must be made to the current I.E.E.WIRING
REGULATIONS and BUILDING REGULATIONS, If the boiler
is to be fitted into a building of timber frame construction then
reference must be made to the Institute of Gas Engineers
document UP 7.

7.0 Site Requirements – page 13

Fig14

7.5 Ventilation of Compartments (Fig. 14)

1. Where the boiler is installed in a cupboard or
compartment, air vents are required (for cooling
purposes) in the cupboard or compartment at high and
low level which may communicate with a room or direct
to outside air.

NOTE: Both air vents must communicate with the same
room or both be on the same wall to outside air

2. Detailed recommendations for air supply are given in
BS 5440: Part 2.

3. An existing cupboard or compartment may be used,
provided that it is modified for the purpose.
Recommendations for air supplies and details of
essential cupboard compartment design are given in
BS 5440: Part 2.

7.6 Gas Supply

1. The gas installation should be in accordance with
BS6891.

2. The connection to the appliance is a ½in BSPT internal
threaded connection located at the rear of the gas
service cock (Fig. 15).

3. Ensure that the pipework from the meter to the
appliance is of adequate size. (22mm pipework must be
connected to the appliance gas service cock. This
should extend for at least 3 meters back towards the
gas meter).

Do not use pipes of a smaller diameter than the
boiler gas connection.

Fig. 15

7.7 Electrical Supply

1. External wiring must be correctly earthed, polarised and
in accordance with current l.E.E. WIRING
REGULATIONS.

2. The mains supply is 230V ~ 50Hz fused at 3A.

NOTE: The method of connection to the electricity supply
must facilitate complete electrical isolation of the appliance.
Connection may be via a fused double-pole isolator with a
contact separation of at least 3mm in all poles and servicing
the boiler and system controls only.

7.8 Condensate Drain

NOTE: Ensure the discharge of condensate complies with

any national or local regulations in force.

1. The condensate outlet terminates in a 1” BSP nut and
seal for the connection of 21.5mm (¾in) plastic
overflow pipe which should generally discharge
internally into the household drainage system. If this is
not possible, discharge into an outside drain is
acceptable.

2. The pipe should run internally as much as possible and
with a 10º (1 in 6) fall to dispose of condensate quickly
to avoid freezing.

7.0 Site Requirements – page 14

Fig. 16 7.9 Flue

Fig. 17

NOTE: Due to the nature of the boiler a plume of water

vapour will be discharged from the flue. This should be
taken into account when siting the flue terminal.

1. The following guidelines indicate the general
requirements for siting balanced flue terminals.
Recommendations for flues are given in BS 5440 Pt.1.

2. If the terminal is fitted within 1 metre (39 in) of a plastic
gutter, within 500mm (19½ in) of a painted eave or a
painted gutter, an aluminium shield of at least 1 metre
(39 in) long should be fitted to the underside of the
gutter or painted surface. An air space of 5mm (3/16 in)
should be left between shield and gutter (Fig. 16).

3. If the terminal discharges onto a pathway or
passageway, check that combustion products will not
cause a nuisance and that the terminal will not obstruct
the passageway.

4. Take into consideration the effect the plume of vapour
may have on neighbours when siting the flue.

5. If a terminal is less than 2 metres (78¾ in) above a
balcony, above ground or above a flat roof to which
people have access, then a suitable terminal guard
must be provided.

Terminal Position with Minimum Distance Fig 17 mm

A Directly below an openable window or other opening,

e.g. an air brick.
B Below gutters, soil pipes or drain pipes.
C Below eaves.
D Below balconies or car port roof.
E From vertical drain pipes and soil pipes.
F From internal or external corners.
G Above ground, roof or balcony level.
H From a surface facing a terminal.
I From a terminal facing a terminal.
J Vertically from a terminal on the same wall.
K Horizontally from a terminal on the same wall.
L For an opening in a car port (e.g. door, window) into a

dwelling.

300

75
200
200

75
300
300
600

1200
1500

300

1200